4 Advice to Choose a Rapid Prototyping in the Automotive Industry

What are the Advantages of Rapid Prototyping?

Done right, rapid prototyping streamlines product development, providing wholly positive results.

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Cost-Effectiveness

Here is an example: Traditional prototyping for injection molding often involves new tooling and molds for each iteration, but creating multiple, expensive steel molds to test a part may not be the best use of this technology. Rapid prototyping aims to save you money by altering that step. One way is to use injection molding with comparatively inexpensive aluminum molds, or prototyping using 3D printing, CNC machining, or sheet metal fabrication, depending on your part design. With any of these, you’ll be able to manufacture your prototype at a fraction of the cost. Depending on your needs, your final iteration can then use injection molding for high-volume production.  

Enhanced Communication and Collaboration  

Rapid prototyping typically involves digital manufacturing processes, which invite collaboration during the iteration phase, using a computer-based model of a part called a digital twin—a virtual version of a physical (or soon-to-be physical) part. The digital twin travels through a virtual version of the manufacturing floor, identifying potential manufacturability issues before the real work begins. Collective stakeholders can identify any issues in the digital version of the file, respond to that, and provide input before final manufacturing begins. Once a prototype has been manufactured, that physical object can be shared with others for their evaluation.  

Accelerate Product Development

When prototyping, you want to use the fastest manufacturing method available to make your parts. That decision will be informed by your end part, but if you just need a part manufactured for which you can test form, fit, and function, it helps to choose the simpler/faster process to enhance iteration speed. As mentioned above, there are solutions that not only speed development, but also reduce costs. 

Greater Product Customization

Rapid prototyping allows for fast tweaks to design so you can customize the parts you need. Whether you intend to offer end users variations of color, material, or functionality, this method will speed manufacturing of individual parts for evaluation.

Improved Design Validation

No one wants to go to full production quantities without proper testing and validation. At the core of rapid prototyping is a process that can detect flaws early in the development process, either via user feedback or functional testing. This can help avoid issues later in your product’s life cycle. 

Ways to Reduce the Cost of Rapid Prototyping 

Something not often thought about is the fact that rapid prototyping gets you your parts faster. That reduces costs because you avoid the expense of waiting for parts and reduce go-to-market delays. Here are some additional ways to reduce costs:  

Use a Digital Manufacturer

Using a digital manufacturer moves your parts from CAD model to prototype faster than traditional manufacturers. It also has the bonus of offering design for manufacturing (DFM) feedback to ensure that your part doesn’t have issues that would prevent it from being manufactured. 

Choose Materials Wisely

Remember, it’s just a prototype. This isn’t your final part. Let’s say your final product needs to be made in an expensive material, such as titanium. If all you need is to confirm basic specifications and fit, any other metal (or in some cases, even plastics) will work well when evaluating part design. 

Drop Surface Finishes

Typically, these are aesthetic or protective coatings that simply are not necessary at this stage. Unless you need to validate the fit of a finished part within your application, eliminating finishes and other secondary operations such as smoothing on prototypes will save you money and time. 

Evaluate Your Design

Think about the elements of each part that are most crucial to you and concentrate on nailing those down. Before prototyping, it helps to have a goal regarding what you would consider a minimum viable prototype (MVP). The MVP allows you to properly evaluate how your part works within the context of your application. Aim for that and you will likely have greater success more quickly. 

Comparing Prototyping Processes

Process Description Finish Example Materials SLA Stereolithography Laser-cured photopolymer

Additive layers of 0.002-0.006 in. (0.051-0.152mm) typical, 0.004 in. (0.mm) maximum layer thickness 

Thermoplastic-like photopolymers SLS Selective Laser Sintering Laser-sintered powder Additive layers of 0.004 in. (0.102mm) typical Nylon, TPU DMLS Direct Metal Laser Sintering Laser-sintered metal powder Additive layers of 0.-0. in. (0.020-0.030mm) typical Stainless steel, titanium, chrome, aluminum, Inconel FDM  Fused Deposition Modeling Fused extrusions Additive layers of 0.005-0.013 in. (0.127-0.330mm) typical ABS, PC, PC/ABS, PPSU MJF Multi Jet Fusion Inkjet array selectively fusing across bed of nylon powder

Additive layers of 0.-0.008 in. (0.089-0.203mm) typical, only 0. in. (0.080mm) offered 

Black Nylon 12 PJET  PolyJet UV-cured jetted photopolymer

Additive layers of 0.-0. in. (0.015-0.030mm) typical, only 0. in. (0.030mm) layers offered 

Acrylic-based photopolymers, elastomeric photopolymers CNC Computer Numerically Controlled Machining Machined using CNC mills and lathes Subtractive machined (smooth) Most commodity and engineering-grade thermoplastics and metals IM Injection Molding Injection-molded using aluminum tooling Molded smooth (or with selected texture), including industrial standard finishes such as SPI grades and Mold-Tech  Most commodity and engineering-grade thermoplastics, metal, and liquid silicone rubber SM Sheet Metal Fabrication Conventional press brake sheet metal fabrication including permanent hardware, and welding   Orbital sanded or straight grain brushed, and “#4” (304-#4 stainless)  Aluminum, stainless, steel, copper, brass, and more 

Pros and Cons of Each Prototyping Process

3D Printing Processes

SLA Stereolithography SLA is an industrial 3D printing, or additive manufacturing, process that builds parts in a pool of UV-curable photopolymer resin using a computer controlled laser. The laser is used to trace out and cure a cross-section of the part design on the surface of the liquid resin. The solidified layer is then lowered just below the surface of the liquid resin and the process is repeated. Each newly cured layer adheres to the layer below it. This process continues until the part is completed. Pros
For concept models, cosmetic prototypes, and complex designs, SLA can produce parts with intricate geometries and excellent surface finishes as compared to other additive processes. Cost is competitive and the technology is available from several sources. Cons
Prototype parts may not be as strong as those made from engineering-grade resins, so the parts made using SLA have limited use for functional testing. Additionally, while parts undergo a UV-cycle to solidify the outer surface of the part, parts built in SLA should be used with minimal UV and humidity exposure so they don’t degrade. SLS Selective Laser Sintering SLS is one of five additive processes available at Protolabs. During the SLS process, a computer-controlled CO2 laser draws onto a hot bed of nylon-based powder from the bottom up, where it lightly sinters (fuses) the powder into a solid. After each layer, a roller lays a fresh layer of powder on top of the bed and the process repeats. SLS uses either rigid nylon or elastomeric TPU powders similar to actual engineering thermoplastics, so parts exhibit greater toughness and are accurate, but have rough surface and lack fine details. SLS offers a large build volume, can produce parts with highly complex geometries and create durable prototypes. Pros
SLS parts tend to be more accurate and durable than SLA parts. The process can make durable parts with complex geometries, and is suitable for some functional testing Cons
The parts have a grainy or sandy texture and the process has a limited resin choice. DMLS Direct Metal Laser Sintering DMLS is an additive manufacturing technology that produces metal prototypes and functional, end-use parts. DMLS uses a laser system that draws onto a surface of atomized metal powder. Where it draws, it welds the powder into a solid. After each layer, a blade adds a fresh layer of powder and repeats the process. DMLS can use most alloys, allowing prototypes to be full-strength, functional hardware made out of the same material as production components. It also has the potential, if designed with manufacturability in mind, to transition into metal injection molding when increased production if needed. Pros
DMLS produces strong (typically, 97 percent dense) prototypes from a variety of metals that can be used for functional testing. Since the components are built layer by layer, it is possible to design internal features and passages that could not be cast or otherwise machined. Mechanical properties parts are equal to conventionally formed parts. Cons
If producing more than a few DMLS parts, costs can rise. Due to the powdered metal origin of the direct metal process, the surface finish of these parts are slightly rough. The process itself is relatively slow and also usually requires expensive post-processing. FDM Fused Deposition Modeling FDM uses an extrusion method that melts and re-solidifies thermoplastic resin (ABS, polycarbonate, or ABS/polycarbonate blend) in layers to form a finished prototype. Because it uses real thermoplastic resins, it is stronger than binder jetting and may be of limited use for functional testing. Pros
FDM parts are moderately priced relatively strong, and can be good for some functional testing. The process can make parts with complex geometries Cons
The parts have a poor surface finish, with a pronounced rippled effect. It is also a slower additive process than SLA or SLS and has limited suitability for functional testing. MJF Multi Jet Fusion MJF uses an inkjet array to selectively apply fusing and detailing agents across a bed of nylon powder, which are then fused by heating elements into a solid layer. After each layer, powder is distributed on top of the bed and the process repeats until the part is complete. When the build finishes, the entire powder bed with the encapsulated parts is moved to a processing station where a majority of the loose powder is removed by an integrated vacuum. Parts are then bead blasted to remove any of the remaining residual powder before ultimately reaching the finishing department where they are dyed black to improve cosmetic appearance. Pros
MJF is fast—producing functional nylon prototypes and end-use production parts in as fast as one day. Final parts exhibit quality surface finishes, fine feature resolution, and more consistent mechanical properties when compared to processes such as SLS. Cons
Currently MJF is limited to PA12 nylon, and SLS has better small feature accuracy (small feature tolerances). PJET PolyJet PolyJet uses a print head to spray layers of photopolymer resin that are cured, one after another, using ultraviolet light. The layers are very thin allowing quality resolution. The material is supported by gel matrix that is removed after completion of the part. Elastomeric parts are possible with PolyJet. Pros
This process is moderately priced, can prototype overmolded parts with flexible and rigid materials, can produce parts in multiple color options, and easily duplicates complex geometries. Cons
PolyJet parts have limited strength (comparable to SLA) and are not suitable for functional testing. While PolyJet can make parts with complex geometries, it gives no insight into the eventual manufacturability of the design. Also, colors can yellow when exposed to light over time. HPS Hybrid PhotoSynthesis HPS technology integrates both a precision laser and a digital light processing (DLP) system to simultaneously image internal and external structures. This dual approach allows the Axtra3D printer to overcome traditional limitations and produce exceptionally detailed parts with unmatched speed and quality. Pros

Cons

CNC Machining

CNC Computer Numerically Controlled Machining In machining, a solid block (or rod stock) of plastic or metal is clamped into a CNC mill or lathe respectively and cut into a finished part through a subtractive process. This method generally produces superior strength and surface finish to any additive manufacturing process. It also has the complete, homogenous properties of the plastic because it is made from solid blocks of extruded or compression molded thermoplastic resin, as opposed to most additive processes, which use plastic-like materials and are built in layers. The range of material choices allows parts to be made with the desired material properties, such as: tensile strength, impact resistance, heat deflection temperatures, chemical resistance, and biocompatibility. Good tolerances yield parts suitable for fit and functional testing, jigs and fixtures, and functional components for end-use applications. A number of manufacturers, including Protolabs, use 3-axis milling and 5-axis indexed milling processes along with turning to manufacture parts in a range of engineering-grade plastics and metals. Pros
Machined parts have good surface finishes and are quite strong because they use engineering-grade thermoplastics and metals. As with 3D printing, custom prototypes can be delivered in as fast as one day due to our proprietary automated processes. Cons
There may be some geometry limitations associated with CNC machining, and it is sometimes more expensive to do this in-house rather than 3D printing processes. Because the process is removing material instead of adding it, milling undercuts can sometimes be difficult and part design should be carefully considered for ease of manufacturing.

Injection Molding

IM Injection Molding Rapid injection molding works by injecting thermoplastic resins into a mold, just as in production injection molding. What makes the process “rapid” is the technology used to produce the mold, which is often made from aluminum instead of the traditional steel used in production molds. Molded parts are strong and have excellent finishes. It is also the industry standard production process for plastic parts, so there are inherent advantages to prototyping in the same process if the situation allows. Almost any engineering-grade plastic or liquid silicone rubber (LSR) can be used, so the designer is not constrained by the material limitations of the prototyping process. Pros
Molded parts are made from an array of engineering-grade materials, have excellent surface finish, and are an excellent predictor of manufacturability during the production phase. Cons
There is an initial tooling cost associated with rapid injection molding that does not occur with any of the additive processes or with CNC machining. So in most cases, it makes sense to do one or two rounds of rapid prototypes (subtractive or additive) to check fit and function before moving to injection molding. 

Sheet Metal Fabrication

SM Sheet Metal Fabrication Conventional press brake forming processes rapidly produce both simple and complex forms. Laser and punch cutting cut geometries and can include punch form features up to 4 in. (101.6mm) in most cases, with longer features available using progressive punch tooling. Protolabs combines this cutting and forming capability with permanent hardware installation including clinch fasteners like those Penn Engineering (PEM) offers, as well as resistance-welded studs and nuts. Highly skilled assemblers are ready to weld or rivet your final designs, as well as finish your parts with in-house powder coating and silkscreen capabilities.  Pros
Most sheet metal geometries can be produced with high precision in a vast array of thicknesses and material types. Cons
Sheet metal is limited in its ability to produce stamped features, and features requiring curved or organic-shaped bend lines. Press brake forming can produce linear bends with an inside bend radius of approximately 0.010 in. (0.25mm) and up.

Choosing a Process

Use the decision tree below to narrow down which factors are of highest importance to you based on where you are in the prototyping process, referring as needed to the definitions below this decision tree infographic.

Rapid Prototyping Applications

Definitions vary and may differ at different organizations, but the definitions below may be used as a starting point.

Concept Model

A physical model made to demonstrate an idea. Concept models allow people from different functional areas to see the idea, stimulate thought and discussion, and drive acceptance or rejection.

Prototyping Considerations

• Speed: turnaround time to convert a computer file into a physical prototype
• Appearance: any visual attribute: color, texture, size, shape, etc. 

Assembly/Fit Testing

Manufacturing some or all parts of an assembly, putting them together, and seeing if they fit properly. At the gross level, this checks for design errors, such as placing two tabs at 2 in. (50.8mm) spacing and the mating slots at 1 in. (25.4mm) spacing. At the fine level, this is a matter of minor dimensional differences and tolerances. Obviously, any test involving tolerances needs to use the actual manufacturing process or one which has similar tolerances. 

Prototyping Considerations

• Form: the shape of the part; features and size
• Fit: how the part mates with other parts

Functional Testing

Evaluating how a part or assembly will function when subjected to stresses representative of what it will see in its actual application.

Prototyping Considerations

• Chemical Resistance: resistance to chemicals including acids, bases, hydrocarbons, fuels, etc.
• Mechanical Properties: strength of the part measured by tensile strength, compressive strength, flexural strength, impact strength, tear resistance, etc.
• Electrical Properties: interaction of electrical fields with the part. This may include dielectric constant, dielectric strength, dissipation factor, surface and volume resistance, static decay, etc.
• Thermal Properties: changes in mechanical properties that occur with changes in temperature. These may include thermal expansion coefficient, heat deflection temperature, Vicat softening point, etc.
• Optical Properties: ability to transmit light. May include refractive index, transmittance, and haze.

Life Testing

Testing properties that may change with time and that are important for a product to remain functional throughout its expected life. Life testing often involves subjecting the product to extreme conditions (e.g., temperature, humidity, voltage, UV light, etc.) to estimate in a shorter period of time, how the product will react during its expected life.

Prototyping Considerations

• Mechanical Properties (fatigue strength): ability to withstand repeated load cycles at various stress levels.
• Aging Properties (UV, creep): ability to withstand exposure to ultraviolet light with an acceptable amount of degradation; ability to withstand extended applications of forces to the part with acceptable levels of permanent deflection.

Regulatory Testing

Testing specified by a regulatory or standards organization or agency to assure parts are suitable for a particular use such as a medical, food service, or consumer application. Examples include Underwriters Laboratory (UL), the Canadian Standards Association (CSA), the U.S. Food and Drug Agency (FDA), the U.S. Federal Communications Commission (FCC), the International Standard Organization (ISO) and the European Commission (EC).

Prototyping Considerations

• Flammability Properties: the resistance of a resin or part to ignition in the presence of a flame.
• EMI/RFI Properties: the ability of a resin, part or assembly to shield or block electromagnetic interference or radio frequency interference.
• Food Rating: approval of a resin or part to be used in applications when it comes in contact with areas where food is prepared, served or consumed.
• Biocompatibility: the ability of the resin or part to be in contact with human or animal bodies, outside or inside the body, without causing undue adverse effects (e.g., irritations, blood interactions, toxicity, etc.). Biocompatibility is important for surgical instruments and many medical devices.

Considerations for Transitioning to Production for Injection Molding During Prototyping 

As mentioned earlier, many engineers use 3D printing for prototyping and then switch over to injection molding for production quantities. It makes sense in terms of cost and time saved. Industries including aerospace and medical device typically take this path during their product’s life cycle. So, how do you set yourself up for success moving from 3D printing to injection molding? Here is a basic overview but note that we also offer more detailed information.

Define Your Part Before Designing 

It is important to put a lot of thought into a part’s design, being cognizant of the different DFM requirements that 3D printing and injection molding have. During prototyping, don’t box yourself into a corner with fancy geometries that print beautifully but can’t be replicated via injection molding. Our interactive DFM feedback during quoting can provide helpful guidance. 

If you want to learn more, please visit our website Rapid Prototyping in the Automotive Industry.

Beyond that, consider the environment your parts will need to withstand. Choose designs and materials that can survive whatever will be thrown at them. 

Using Multiple Prototypes 

Designing and manufacturing multiple prototypes enables you to explore different design options, features, or aesthetic variations without committing to the costly tooling for injection molding too early. This allows for a more comprehensive understanding of what works best for the intended application and market. It also speeds up the period of time necessary to evaluate different iterations. 

Maneuvering Through Molding 

Transitioning to injection-molded parts requires specific design methods such as uniform wall thickness and draft angles. Maintaining a uniform wall thickness ensures the mold fills evenly, preventing defects. Adding draft angles to the design facilitates the easy ejection of the part from the mold. These are considerations that must be included when moving to injection molding, even if not present in a 3D-printed prototype. 

Choosing Materials 

Even the same material can act differently when printed vs. molded. Material selection for injection molding depends on various properties, including mechanical, physical, and thermal characteristics. Manufacturability, including resin flow and how well it fills the mold features, is essential. Cosmetic appearance and cost also play significant roles in the material selection process. 

Mitigating Costs and Timelines 

Prototyping using 3D printing is often the fastest way to iterate. Changes can be made in a CAD model, leading to quick turnaround of your updated prototype. While cost and deadlines are crucial factors, using affordable production methods can help control costs. Digital manufacturing can also accelerate product development, shortening both prototyping and production timelines. This approach helps optimize the overall efficiency of the transition from prototyping to production. 

Summary

Prototype models help design teams make more informed decisions by obtaining invaluable data from the performance of, and the reaction to, those prototypes. The more data that is gathered at this stage of the product development cycle, the better the chances of preventing potential product or manufacturing issues down the road. If a well thought out prototyping strategy is followed, there is a far greater chance that the product will be introduced to the market on time, be accepted, perform reliably, and be profitable.

What is the best way to get a prototype made? The answer depends on where you are in your process and what you are trying to accomplish. Early in the design process, when the ideas are flowing freely, concept models are helpful. As the design progresses, a prototype that has the size, finish, color, shape, strength, durability, and material characteristics of the intended final product becomes increasingly important. Therefore, using the right prototyping process is critical. In order to most effectively validate your design, pay close attention to these three key elements of your design: functionality, manufacturability, and viability. 

If your prototype can faithfully represent the attributes of the end-product, it is by definition functional. These requirements often include such things as material properties (e.g., flame resistance), dimensional accuracy for fit-up with mating parts, and cosmetic surface finishes for appearance.

If your prototype design can be repeatedly and economically produced in a manner that supports the requirements of the end product, it is by definition manufacturable. These requirements include the ability to maintain the functionality of the design as described above, keep the piece-part cost below the required level, and support the production schedule. No matter how great a design is, it will go nowhere if it can’t be manufactured. Make sure your prototyping process takes this into consideration.

Finally, even if your prototype design is functional and manufacturable, it doesn’t mean anyone will want to use it. Prototypes are the only true way to verify the viability of the design in this sense. If your design can also pass the challenges associated with market trials (e.g., trade show displays, usability testing) and regulatory testing (e.g., FDA testing of medical devices), you’re well on your way to a successful product launch.

Choosing the right rapid prototyping technology is a crucial step in the product development process. Rapid prototyping allows for quick and cost-effective creation of physical prototypes, helping to validate and iterate on design concepts before full-scale production. With a variety of prototyping technologies available, selecting the most suitable one for your project requires careful consideration of various factors. In this article, we'll explore key considerations to help you make an informed decision.

1. Project Requirements

Begin by clearly defining the requirements of your project. Consider factors such as the size and complexity of the prototype, desired material properties, and the level of detail required. Different rapid prototyping technologies excel in specific areas, so aligning your project requirements with the capabilities of the chosen technology is essential.

2. Material Compatibility

The choice of materials is critical in prototyping, as it directly influences the functional and aesthetic qualities of the prototype. Different rapid prototyping technologies support various materials, ranging from plastics and resins to metals. Ensure that the selected technology is compatible with the material that best suits your project's needs.

3. Accuracy and Resolution

Evaluate the required level of accuracy and resolution for your prototype. Some applications demand high precision, while others may tolerate lower levels. Technologies like stereolithography (SLA) and selective laser sintering (SLS) typically offer finer details compared to fused deposition modeling (FDM). Assess the dimensional accuracy and layer resolution offered by each technology to meet your specific requirements.

4. Speed of Prototyping

Consider the time constraints of your project. Different rapid prototyping technologies vary in their speed of production. For quick iterations and shorter development cycles, technologies like FDM and SLA are known for their rapid prototyping capabilities. However, if speed is not a critical factor, you may opt for technologies that provide better accuracy and surface finish at a slower pace.

5. Cost Considerations

Budget constraints are a significant factor in any project. Evaluate the cost of equipment, materials, and post-processing for each prototyping technology. While some technologies may have higher initial costs, they could prove cost-effective in the long run due to reduced material waste, faster prototyping times, or lower maintenance requirements.

6. Prototype Size

The size of your prototype is a key consideration. Some technologies are better suited for small, detailed models, while others excel at producing larger prototypes. If your project involves a mix of both, choose a technology that can accommodate the range of sizes required.

7. Iteration Requirements

Consider the iteration cycle of your project. Some rapid prototyping technologies are better suited for quick and frequent iterations, allowing for efficient design changes. Technologies that require longer production times or extensive post-processing may hinder an agile development process.

8. Post-Processing Needs

Examine the post-processing requirements of each rapid prototyping technology. Some technologies, like SLA, may require additional steps to clean, cure, or finish the prototypes. Understanding the post-processing needs is crucial for planning the overall timeline and resource allocation for your project.

9. Accessibility of Materials and Equipment

Ensure that the materials and equipment required for your chosen prototyping technology are readily available. Limited availability of materials or specialized equipment can lead to delays and increased costs.

10. Environmental Impact

Consider the environmental impact of the prototyping technology. Some technologies may generate more waste or have higher energy consumption. Choosing a technology with a smaller ecological footprint aligns with sustainable and responsible product development practices.

In conclusion, selecting the right rapid prototyping technology involves a thoughtful evaluation of project requirements, material compatibility, accuracy, speed, cost considerations, prototype size, iteration needs, post-processing requirements, accessibility of materials and equipment, and environmental impact. By carefully weighing these factors, you can make an informed decision that aligns with the goals of your project and ensures successful prototype development.

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